Rotatable blade apparatus with individually adjustable blades

ABSTRACT

The lengths and/or chords and/or pitches of wind turbine or propeller blades are individually established, so that a first blade can have a length/chord/pitch that is different at a given time to the length/chord/pitch of a second blade to optimize performance and/or to equalize stresses on the system.

FIELD OF THE INVENTION

The present invention relates generally to rotatable blades for windturbines, and more particularly to blade assemblies for wind turbinesand propellers in which the parameters of chord, length, and pitch canbe individually adjusted for each blade.

BACKGROUND OF THE INVENTION

Variable pitch propellers have been provided in which the pitch of allblades can be simultaneously changed as appropriate to, e.g., reducecavitation depending on the speed of rotation of the blades. An exampleof such a system is disclosed in U.S. Pat. No. 5,733,156, incorporatedherein by reference.

In the wind turbine art, U.S. Pat. No. 6,972,498, incorporated herein byreference, provides a wind turbine blade assembly in which the lengthsof the blades may be simultaneously changed to account for changing windspeed, imbalances, and control system loads. As understood herein, itwould be desirable, for each blade individually, to establish the lengthand/or chord and/or pitch of the blade.

SUMMARY OF THE INVENTION

A wind turbine blade assembly or a propeller blade assembly has at leastfirst and second blades coupled to a rotor defining an axis of rotation.The tip of the first blade is positioned a first distance from the axisof rotation at a first time, while the tip of the second blade ispositioned a second distance from the axis of rotation at the firsttime, with the first and second distances not being equal.

In some implementations, at least one blade has respective plural partstelescoping relative to each other along the length of the blade. Eachblade defines a respective length, and the lengths are different fromeach other at least at the first time. An actuator can telescope onepart of a blade relative to another part of the blade. In some aspectsplural actuators can be provided to telescope plural parts. The actuatormay be supported on the blade and may receive power through a slip ring.Or, the blades can move longitudinally as they ride against a camsurface. The lengths of the blades may be established based onrespective pressure signals representative of fluid pressure on theblades, and/or based on respective angular positions of the blades.

In another aspect, a wind turbine blade assembly or a propeller bladeassembly has at least first and second blades coupled to a rotordefining an axis of rotation. The first blade defines a first chord at afirst time, the second blade defines a second chord at the first time,and the first and second chords are not equal.

In still another aspect, a wind turbine blade assembly or a propellerblade assembly has at least first and second blades coupled to a rotordefining an axis of rotation. The first blade defines a first pitch at afirst time, the second blade defines a second pitch at the first time,and the first and second pitches are not equal.

In another aspect, a method for operating a wind turbine includesestablishing a first value for a first parameter of a first blade at afirst time, and establishing a second value for the first parameter of asecond blade at the first time. According to this aspect, when theblades are disposed in wind, they rotate to cause the wind turbine toproduce electrical power.

In another aspect, a wind turbine has an upright support, a rotorcoupled to the support, and at least first and second blades coupled tothe rotor to cause it to rotate when wind passes the blades. Each bladehas first and second configurations. The first configuration of thefirst blade is identical to the first configuration of the second bladeand the second configuration of the first blade is identical to thesecond configuration of the second blade. As set forth further below,the first blade assumes the first configuration at a first time and thesecond blade assumes the second configuration at the first time.

The details of the present invention, both as to its structure andoperation, can best be understood in reference to the accompanyingdrawings, in which like reference numerals refer to like parts, and inwhich:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a wind turbine in accordance with presentprinciples;

FIG. 2 is a schematic view of a vessel propeller in accordance withpresent principles;

FIG. 3 is a block diagram showing control elements in accordance withone embodiment;

FIG. 4 is a block diagram showing control elements in accordance withanother embodiment;

FIG. 5 is a perspective view of a blade in the extended configuration;

FIG. 6 is a plan view of a blade, showing one preferred non-limitingpressure sensor disposition on the blade;

FIG. 7 is a block diagram of one actuator embodiment, in which a singlemotor moves plural blade segments;

FIG. 8 is a block diagram of one actuator embodiment, in whichrespective motors move respective blade segments;

FIG. 9 is a perspective view of a non-limiting actuator;

FIG. 10 is an elevational view of an alternative cam-based system;

FIG. 11 is a plan view showing that the present principles, in additionto being applied to change the length of a blade, may also be applied inchanging the chord and/or pitch of the blade; and

FIG. 12 is a view of a cam-based system for adjusting blade pitch, withportions of the caroming surface broken away for clarity.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring initially to FIG. 1, a wind turbine blade assembly is shown,generally designated 10, which includes first and second blades 12, 14that are coupled to a rotor 16, it being understood that presentprinciples apply to two, three, or more blades. The rotor 16 isrotatably supported above the surface 18 of the earth by an uprightsupport 20, which holds the blades 12, 14 in a vertical plane above theearth's surface as shown. In accordance with principles known in theart, wind flowing past the blades causes them to turn to thereby causean associated generator, shown schematically at 21, to generate electricpower.

The rotor 16 defines an axis 22 of rotation, and in accordance withdisclosure below at least the first blade 12 and preferably both blades12, 14 can be moved between a long configuration and a shortconfiguration, as well as to intermediate configurations therebetween,and the blade 12 is not constrained to be in the same configuration asthe second blade 14. Thus, to illustrate, FIG. 1 shows that the blade 12has a blade tip 24 that can be configured to be a relatively longdistance d₁ from the axis 22 of rotation. Simultaneously, the tip 26 ofthe second blade 14 can be configured to be a second distance d₂ fromthe axis 22 of rotation, with the distances d₁, d₂ being unequal whenpresent principles are applied. For purposes that will shortly becomeclear, one or more pressure sensors 28 can be disposed on one or bothblades 12, 14. Alternatively, wind speed sensors on the blades 12, 14 orelsewhere can be used.

As set forth further below, the principles outlined herein in terms ofvariable length also apply to variable pitches and chords, so that inaddition to or in lieu of different lengths, the pitches and/or chordsof the respective blades 12, 14 may be different from each other at thesame point in time. It is to be further understood that the assembly 10may also, at other times, embody conventional operating principleswherein the blades 12, 14 are identically configured in length, chord,and pitch.

FIG. 2 shows that the present principles can also be applied to apropeller blade assembly 30 that has at least first and second blades32, 34, and potentially additional blades 36, coupled to a rotatablerotor 38 that defines an axis 40 of rotation. The tip 42 of the firstblade 32 can be configured to be a first distance from the axis 40 ofrotation and simultaneously the tip 44 of the second blade 34 can beconfigured to be a further distance from the axis 40 of rotation than isthe tip 42 of the first blade 32. A shaft 46 of a waterborne vessel 48can hold the blades 32, 34, 36 in a vertical plane (at neutral vesselpitch) as shown.

As set forth further below, the principles outlined herein in terms ofvariable length also apply to variable pitches and chords, so that inaddition to or in lieu of different lengths, the pitches and/or chordsof the respective blades 32, 34, 36 may be different from each other atthe same point in time. It is to be further understood that the assembly30 may also, at other times, embody conventional operating principleswherein the blades are identically configured in length, chord, andpitch.

For illustration purposes the disclosure below focuses on a wind turbineapplication, it being understood that the principles embodied thereinmay be applied to the propeller assembly 30, in which, e.g., the blade34 has plural portions 50 that can telescope or otherwise move in theaxial dimension of the blade 34 relative to each other (and, as statedabove, potentially can also move relative to each other in the chorddimension).

FIGS. 3 and 4 show various system configurations for controlling thelengths (and/or chords and/or pitches) of the blade 12, and preferablyalso of the blade 14. A controller or processor 52 can receive inputfrom the pressure sensors 28 on the blades and/or from an encoder 54that outputs a signal representing the angular position of the rotor 16.The controller or processor 52 controls an actuator with motor 56 toestablish the length (and/or chord and/or pitch) of the blades. Themotor may be a stepper motor or other appropriate motor, and as setforth further below may be located within the blade 12 or outside theblade 12. From time to time herein, “actuator” may be used to refer toboth a motor and the linkages that couple the motor to the movable bladeportions, and to just the linkages themselves.

In some implementations, the length of each blade 12, 14 is establishedbased on its angular position. Thus, in non-limiting embodiments a bladecan assume the long configuration when at the top dead center position(pointing straight up vertically from the rotor) and the shortconfiguration in the opposite position, and can have intermediatelengths when moving therebetween. In terms of the two blade applicationof FIG. 1, the first blade 12 is in the long configuration at the sametime the second blade 14 is in the short configuration.

In addition to or in lieu of using angular position to establish thelengths of the blades, the lengths of the blades can depend onrespective pressure signals from the sensors 28, which arerepresentative of fluid pressure on the blades. In this embodiment, thecontroller or processor 52 establishes blade length both to optimizeperformance while minimizing load imbalances on the rotor by, e.g.,establishing blade lengths that result in equal pressures on both blades12, 14 while providing optimum length based on wind speed, to ensurethat the blades rotate as fast as feasible while remaining below angularvelocity limits.

FIG. 4 shows further details of the controls of one illustrativenon-limiting embodiment. As shown, the pressure sensors 28 on the blade12 are electrically connected to a sensor bus 58 within the blade. Thebus 58 is connected to the controller or processor 52 through a slipring connector array 60, which, in accordance with slip ring principlesknown in the art, permits relative rotational movement between the blade12 and the controller 52 while maintaining electrical connectivitybetween them. A bidirectional data bus 59 can be provided between theslip ring connector array 60 and the controller 52 to permit thecontroller 52 to receive pressure signals and to output control signalsto the actuators discussed below.

More particularly, electrical power, as well as control signals from thecontroller 52, is also provided through the slip ring to one or moreactuator subsystems 62, each of which can include a respective motor anda respective linkage that connects the actuator to a respective bladeportion to move the blade portion. Alternatively, a single motor may beprovided within the blade 12 and linked through gears or other linkagesas set forth further below to move each of plural individual actuatorsubsystems that, in such a circumstance, would include only linkages torespective blade portions.

FIGS. 5-8 show further details of non-limiting implementations of thepresent blade. As shown in FIG. 5 and using the first blade 12 as anexample, the blade can have plural portions 64 that move relative toeach other in the length dimension of the blade, it being understoodthat similar principles apply to expand and contract the blade in thechord dimension. As shown at 66, an actuator linkage can be coupled totwo adjacent substantially rigid hollow blade portions 64 to move theblade portions relative to each other. In the embodiment shown in FIG.5, the blade portions abut each other along their transverse edges inthe short configuration, with facing transverse edges of adjacent bladeportions being distanced from each other in the long configuration and,if desired, a flexible membrane 68 (portions of which are removed inFIG. 5 to show the linkage 66) can enclose the space between theportions.

FIG. 6 shows that the pressure sensors 28 can be arranged in two linesalong the length of the blade 12, with one line of sensors beingdisposed on a first side of the “twist” 70, or blade surface aspectchange line, and with a second line of sensors being disposed on theopposite side of the twist as shown.

FIG. 7 shows that in some implementations, a single motor 72 can beprovided in the blade 12 to turn a lead screw 74 or equivalentstructure, with plural nuts 76 or equivalent linking structure riding onthe lead screw 74 and connected to respective blade portions to move theblade portions.

In contrast, FIG. 8 shows that each of plural movable blade portions 80,82 can house its own respective motor and linkage that connects theblade portion to the distally successive blade portion. Thus, the bladeportion 80 has a motor 84 with linkage 86 that extends between the bladeportions 80, 82 to move the medial blade portion 82 outward from theproximal blade portion 80. Likewise, the medial blade portion 82supports a motor 88 with associated linkage 90 extending to a distalblade portion 92, to move the distal blade portion 92 outward from themedial blade portion 82. Additional blade portions with motors andlinkages may be provided. As mentioned earlier, power can be supplied tothe motors through a power line 94 and slip ring assembly 96, and dataand control signals can be exchanged through the slip ring assembly 96and data bus 98 within the blade 12.

As also shown in FIG. 8, instead of using a flexible membrane 68 (FIG.5) between adjacent blade portions, each adjacent blade portion can, inthe short configuration, be partially nested within the immediatelyproximal portion. Accordingly, in the short configuration thesub-portion 100 (with parts broken away in FIG. 8 to expose the linkage86) of the medial blade portion 82 is nested within the proximal bladeportion 80, whereas in the long configuration shown the sub-portion 100is telescoped distally beyond the proximal portion 80. All portions ofthe blade in this embodiment can be substantially rigid. Similarly, asub-portion 102 (part of which is removed in FIG. 8 to expose thelinkage 90) of the distal blade portion 92 is nested within the medialportion 82 in the short configuration and is telescoped distally beyondthe medial portion 82 in the long configuration.

FIG. 9 shows an illustrative non-limiting example of one of the motoractuators shown in FIG. 8. A motor 104 such as DC motor is affixed toone blade portion (not shown) to turn a pinion gear 106, whichtranslates rotational motion to longitudinal (with respect to the blade)translational movement of a rack 108. The rack 108 is affixed to thesuccessive blade portion 110, to move it toward and away the bladeportion that supports the motor 104.

When the length of the blade is sought to be changed only based onangular position, FIG. 10 shows that instead of using motor actuators,each blade 110, 112 of a wind turbine or propeller can have proximal anddistal portions 114, 116 that telescope relative to each other as theblade, which is attached to a rotor 117, rotates past a cam 118 on whicha part of the blade between the portions 114, 116 ride. The contour ofthe surface of the cam is established to establish the desiredlength-to-angular position relationship. Other mechanisms, includinggearing, can be employed.

Other mechanisms for moving a blade are disclosed in U.S. Pat. No.6,972,498, modified as appropriate to permit the individualestablishment of the length of each blade, independently of otherblades, as described above.

FIG. 11 schematically illustrates that individual blade configurationmay be independently established not just in the length dimension bylength adjustment actuators 120 but alternatively or additionally in thechord dimension by chord adjustment actuators 122 and/or in the pitchdimension by a pitch adjustment actuator 124, which rotates the bladeabout its hub using, as non-limiting examples, the mechanisms describedin U.S. Pat. No. 5,733,156. In any case, it is to be appreciated thatthe length and/or chord and/or pitch of each blade of the present windturbine or propeller can be established independently of the lengthand/or chord and/or pitch of one or more other blades as necessary toequalize fluid pressure on the blades, to optimize performance by, e.g.,attaining an optimum speed of rotation, and in the case of propellers tolower the rudder profile as necessary to avoid cavitation or even toassist in turning the vessel.

FIG. 12 shows a view similar to that of FIG. 3 with the addition of acamming surface 200, the contoured surface of which faces outwardlyrelative to a rotor 202 to bear against an inner surface 204 of a blade206, which is rotatably coupled at its root 208 to the rotor 202 torotate as the blade rides against the surface 200.

While the particular ROTATABLE BLADE APPARATUS WITH INDIVIDUALLYADJUSTABLE BLADES is herein shown and described in detail, it is to beunderstood that the subject matter which is encompassed by the presentinvention is limited only by the claims. For instance, the principlesdescribed herein could be applied to airplane propellers and tohelicopter rotor blades.

What is claimed is:
 1. A wind turbine blade assembly comprising: atleast first and second blades coupled to a rotatable rotor defining anaxis of rotation, the first blade having a first blade tip being a firstdistance from the axis of rotation at a first time, the second bladehaving a second blade tip being a second distance from the axis ofrotation at the first time, the first and second distances not beingequal, wherein the distances are based on respective angular positionsof the blades relative to the rotor independently of forces on theblades, the first distance being longer than the second distance, thefirst blade tip being at top dead center relative to the rotor at thefirst time, wherein the first blade has at least one of: its pitch, orits chord, being different from that of the second blade at the firsttime.
 2. The assembly of claim 1, wherein at least one blade hasrespective plural parts telescoping relative to each other along thelength of the blade, each blade defining a respective length, thelengths being different from each other at least at the first time. 3.The assembly of claim 2, comprising at least one actuator telescoping atleast one part of a blade relative to another part of the blade.
 4. Awind turbine blade assembly comprising: at least first and second bladescoupled to a rotatable rotor defining an axis of rotation, the firstblade having a first blade tip being a first distance from the axis ofrotation at a first time, the second blade having a second blade tipbeing a second distance from the axis of rotation at the first time, thefirst and second distances not being equal, wherein the distances arebased on respective angular positions of the blades relative to therotor independently of forces on the blades, the first distance beinglonger than the second distance, wherein at least one blade hasrespective plural parts telescoping relative to each other along thelength of the blade, each blade defining a respective length, thelengths being different from each other at least at the first time, atleast one actuator telescoping at least one part of a blade relative toanother part of the blade, wherein at least one blade has at least threeparts and at least two actuators telescoping respective parts.
 5. Theassembly of claim 3, comprising a movable actuator.
 6. The assembly ofclaim 5, wherein the actuator is supported on the blade and receivespower through a slip ring.
 7. The assembly of claim 1, wherein theblades move as they ride against a cam surface.
 8. The assembly of claim1, comprising an upright support holding the blades in a vertical planeabove the earth's surface.
 9. A wind turbine blade assembly comprising:at least first and second blades coupled to a rotor defining an axis ofrotation, the first blade defining a first pitch at a first time, thesecond blade defining a second pitch at the first time, the first andsecond pitches not being equal, wherein the pitches are based onrespective angular positions of the blades with respect to the rotor, amotor being coupled to at least one blade to establish the pitch of theblade.
 10. The assembly of claim 9, comprising an upright supportholding the blades in a vertical plane above the earth's surface.
 11. Awind turbine blade assembly comprising: at least first and second bladescoupled to a rotor defining an axis of rotation, the first bladedefining a first pitch at a first time, the second blade defining asecond pitch at the first time, the first and second pitches not beingequal, wherein the pitches are based on respective angular positions ofthe blades with respect to the rotor, wherein the first blade has atleast one of: its chord, or its length, being different from that of thesecond blade at the first time.
 12. A wind turbine blade assemblycomprising: at least first and second blades coupled to a rotor definingan axis of rotation, the first blade defining a first pitch at a firsttime, the second blade defining a second pitch at the first time, thefirst and second pitches not being equal, wherein the pitches are basedon respective angular positions of the blades with respect to the rotor,wherein the pitches are established based on respective pressure signalsrepresentative of fluid pressure on the blades.
 13. A propeller bladeassembly comprising: at least first and second blades coupled to a rotordefining an axis of rotation, the first blade having a first blade tipbeing a first distance from the axis of rotation at a first time, thesecond blade having a second blade tip being a second distance from theaxis of rotation at the first time, the first and second distances notbeing equal, the first distance being longer than the second distance,the first blade tip being at top dead center relative to the rotor atthe first time, wherein at least one blade has respective plural partstelescoping relative to each other along the length of the blade, eachblade defining a respective length, the lengths being different fromeach other at least at the first time, comprising at least one actuatortelescoping at least one part of a blade relative to another part of theblade, comprising a motor moving at least a portion of an actuator. 14.The assembly of claim 13, wherein at least one blade has at least threeparts and at least two actuators telescoping respective parts.
 15. Theassembly of claim 13, wherein the motor is supported on the blade andreceives power through a slip ring.
 16. The assembly of claim 13,wherein the blades move as they ride against a cam surface.
 17. Theassembly of claim 13, comprising a waterborne vessel shaft holding theblades in a vertical plane.
 18. The assembly of claim 13, wherein thefirst blade has at least one of: its pitch, or its chord, beingdifferent from that of the second blade at the first time.
 19. Theassembly of claim 13, wherein the lengths are established based onrespective pressure signals representative of fluid pressure on theblades.
 20. The assembly of claim 13, wherein the distances are based onrespective angular positions of the blades.
 21. A propeller bladeassembly comprising: at least first and second blades coupled to a rotordefining an axis of rotation, the first blade defining a first chord ata first time, the second blade defining a second chord at the firsttime, the first and second chords not being equal, a waterborne vesselshaft holding the blades in a vertical plane.
 22. The assembly of claim21, wherein at least one blade has respective plural parts telescopingrelative to each other along the chord dimension of the blade.
 23. Theassembly of claim 22, comprising at least one actuator telescoping atleast one part of a blade relative to another part of the blade.
 24. Theassembly of claim 23, wherein at least one blade has at least threeparts and at least two actuators telescoping respective parts.
 25. Theassembly of claim 23, comprising a movable actuator.
 26. The assembly ofclaim 25, wherein the actuator is supported on the blade and receivespower through a slip ring.
 27. The assembly of claim 21, wherein theblades move as they ride against a cam surface.
 28. The assembly ofclaim 21, wherein the first blade has at least one of: its pitch, or itslength, being different from that of the second blade at the first time.29. A propeller blade assembly comprising: at least first and secondblades coupled to a rotor defining an axis of rotation, the first bladedefining a first chord at a first time, the second blade defining asecond chord at the first time, the first and second chords not beingequal, wherein the chords are established based on respective pressuresignals representative of fluid pressure on the blades.
 30. The assemblyof claim 21, wherein the chords are based on respective angularpositions of the blades.
 31. A propeller blade assembly comprising: atleast first and second blades coupled to a rotor defining an axis ofrotation, the first blade defining a first pitch at a first time, thesecond blade defining a second pitch at the first time, the first andsecond pitches not being equal, no other blade defining the first pitchat the first time other than the first blade, a waterborne vessel shaftholding the blades in a vertical plane.
 32. The assembly of claim 31,comprising an actuator coupled to at least one blade to establish thepitch of the blade.
 33. The assembly of claim 31, wherein the bladesmove as they ride against a cam surface.
 34. A propeller blade assemblycomprising: at least first and second blades coupled to a rotor definingan axis of rotation, the first blade defining a first pitch at a firsttime, the second blade defining a second pitch at the first time, thefirst and second pitches not being equal, no other blade defining thefirst pitch at the first time other than the first blade, wherein thefirst blade has at least one of: its chord, or its length, beingdifferent from that of the second blade at the first time.
 35. Apropeller blade assembly comprising: at least first and second bladescoupled to a rotor defining an axis of rotation, the first bladedefining a first pitch at a first time, the second blade defining asecond pitch at the first time, the first and second pitches not beingequal, no other blade defining the first pitch at the first time otherthan the first blade, wherein the pitches are established based onrespective pressure signals representative of fluid pressure on theblades.
 36. The assembly of claim 31, wherein the pitches are based onrespective angular positions of the blades with respect to the rotor.